Biogas Plant based on Cattle Dung at Haibowal Dairy Complex, Ludhiana

Background Note

Biogas Plant at Haibowal Dairy Complex, Ludhiana

During the last many years Ministry of New & Renewable energy (MNRE), GOI is implementing several demonstration projects around High Rate Bio-Methanation Processes. The main objective of these projects is to demonstrate various technologies for the conversion of different types of waste into energy which can eventually lead to generation of electrical power/CBG. The “waste to energy conversion plant” at Haibowal Ludhiana is one of them which utilizes cattle waste dung for generation of 1MW electricity and highly nutrient rich organic fertilizer. It is important to mention here that this project has been set up as one of the demonstration sub projects under UNDP/GEF assisted project on High-Rate Bio Methanation Processes being executed by the MNRE, Government of India. Punjab Energy Development Agency (PEDA) was the implementing agency and own the facility.

The project has been developed on 2.5 acre of land provided by Municipal Corporation Ludhiana. There is abundant quantity of cattle dung available, and the project requirement of dung is about 235 Ton per day. In 2017, plant has been fully converted to CBG plant. The plant has generated employment to 25 Direct and approx. 70 indirect employments to run the plant successfully. This is a ZLD (Zero Liquid Discharge) plant, meaning no untreated or treated liquid waste is released into the environment.

BRIEF DESCRIPTION OF THE PLANT

• 1. Dissolution (Homogenization of Raw Manure) – The fresh cattle dung is blended in a collection tank to provide a waste of uniform characteristics and a waste feed with a solid concentration not exceeding 10%.
• 2. Anaerobic Digestion (BIMA Digestor) - The plant involves the emerging concept of anaerobic digestion. Sophisticated design of Biogas induced Mixing Arrangement, BIMA Digesters, utilizes the homogenized (diluted) cow waste, where stabilization takes place with the production of biogas. The main advantages of BIMA digesters are its mixing system (doesn’t requires mechanical moving part), ability to control scum/sediments and handle high solids concentration. A biological desulphurization unit has been installed in the digester to reduce the H2S concentration.
• 3. Biogas Collection - The biogas, which is produced as a result of stabilization of the waste, leaves the BIMA digester automatically to the gas holder. The biogas would have a composition of 55-65% methane and 30-40% carbon dioxide. In place of a conventional gas holder which is prone to corrosion, a dry type of gas holder, which is made of a synthetic membrane (polyester) and suspended in concrete silo, has been installed in the plant.
• 4. Bio-fertilizer Production – The digested substrate leaving the digester is taken up for dewatering in a screw press. It shows a much better availability of nutrients for the plant due to its biochemical composition, which is almost free of odour and can be precisely applied due to its homogeneity. Plant can produce bio manure upto 30-35 metric ton per day. Further Two types of manure are produced in the plant: FOM (Fermented Organic Manure) and LFOM (Liquid Fermented Organic Manure). These organic manures are sold in the market and contribute to environmental sustainability by promoting eco-friendly agricultural practices and reducing the use of chemical fertilizers.
• 5. Bio-Gas Purification unit – An RBG-to-CBG purification plant upgrades raw biogas generated from organic waste by removing impurities such as CO₂, H₂S, moisture, etc. to obtain high-purity biomethane. The purified gas is then compressed to produce Compressed Biogas (CBG), which can be used as a clean renewable fuel for vehicles, industries, or piped gas networks. These plants help convert agricultural, municipal, and industrial organic waste into sustainable energy while reducing greenhouse gas emission.

Currently, the CBG facility is catering to about 190-200 tons of cattle dung per day for CBG. The first lot of bio-CNG cascade were supplied to Indian Oil Corporation Limited (IOCL) on 28.04.2021.